Method of manufacturing molded article

ABSTRACT

A method of manufacturing a design-imprinted molded article comprises providing a glass mold of a desired shape, that further comprises a desired shaped concave and a desired shaped rim, providing a plurality of sheets of polyacrylonitrile fibers, providing at least one design cutout of polyacrylonitrile fibers, overlaying the plurality of sheets on the surface of the desired shaped concave and desired shaped rim, overlaying the design cutout on the plurality of sheets, and applying high heat to the glass mold.

INCORPORATION BY REFERENCE

This application is a divisional application of and claims the benefitof priority under 35 U.S.C. 121 to the filing date of U.S. applicationSer. No. 16/053,689, entitled “METHOD OF MANUFACTURING MOLDED ARTICLE,”filed on 2018 Aug. 2, and which is incorporated herein by reference inits entirety.

FIELD OF USE

The present disclosure relates generally to a method of manufacturing amolded article, and more particularly to a method of manufacturinghard-sided luggage comprising design element(s).

BACKGROUND

Luggage is commonly soft-sided or hard-sided. The majority of luggage issoft-sided. Canvas, nylon and other similar fabric materials are used tomanufacture soft-sided luggage. To construct soft-sided luggage,non-shape retaining sheets of fabric material can be assembled together,for example, by sewing. Alternatively, shape-retaining sheets of fabricmaterial can also be used to provide some structure to the componentparts. However, soft-sided luggage has the disadvantage of high materialcost, high assembly cost and increased overall weight of requiredconstruction materials. The increased weight becomes a major drawback tosuch methods of luggage construction and in addition there are alsodrawbacks and limitations on style designs.

With regard to soft-sided luggage, a design element may be affixed asthrough sewing or adhesive as well as imbedded into the material asthrough embroidering. Further, where soft-sided materials such as fabricare used for construction, the outward design and appearance of theluggage may be agreeable esthetically and to the touch, but whenexternal forces are applied, the force is directly transferred to thecontents of the luggage. In order to overcome this disadvantage ofsoft-sided luggage, it has been suggested that a structure with a squareframe be inserted into the body of the luggage to maintain a shape ofthe luggage. However, this structure is incapable of maintaining thecontents in the luggage in their original form and adds additional costin materials and increases the overall weight of the luggage furtheradding drawbacks to this current iteration. Additionally, less securityis afforded by soft-sided luggage as thieves are able to cut throughfabric to break into the luggage. Further, soft-sided luggage commonlycomprises external pockets which can be susceptible to receivingunwanted items that are put in without an owner's knowledge furthercompromising the safety of the soft-sided luggage. Finally, the fabricmaterial used for soft-sided luggage is prone to wear and tear by, forexample, fraying, pulling or ripping. This also leads to decreasedsecurity as contents may fall out of holes. This increased proclivity towear and tear further reduces the already limited ability of soft-sidedluggage to provide protection for the items inside the luggage. As such,soft-sided luggage is less likely to have the ability to absorb theimpact from bumps and knocks leaving the contents vulnerable to damageor destruction.

On the other hand, benefits of hard-sided luggage include its improvedstrength as well as reduced weight. Additionally, security is improvedby hard-sided luggage because the hard shell reduces theft through caseslitting or tampering with the external pockets. Further, maximumpacking space is achieved by hard-sided luggage due to the thin shellconstruction as the packing space inside is not given over to folds offabric and lining. Protection of a user's belongings is also improvedwith hard-sided luggage as the hard shells are very durable andresilient. If luggage is dropped, hard-sided luggage offers betterimpact resistance and therefore better protects fragile items inside.However, hard-sided luggage is commonly constructed by repeatedoverlaying of material in the same direction therefore leaving thesurface to bear a homogenous pattern throughout the entire finishedproduct. Further, the resulting finished luggage is devoid of markingsor logos which will leave the luggage unbranded and free ofdifferentiation or source origin through a marking or logo. In order toallow for customization or for purposes of displaying brand for example,a method of incorporating a design to the finished surface of theluggage is required.

SUMMARY OF ILLUSTRATIVE EMBODIMENTS

In one aspect, a method of manufacturing a design-imprinted moldedarticle is disclosed comprising, providing a glass mold of a desiredshape; said glass mold further comprises a desired shaped concave and adesired shaped rim; providing a plurality of sheets of polyacrylonitrilefibers; providing at least one design cutout of polyacrylonitrilefibers; overlaying said plurality of sheets on the surface of saiddesired shaped concave and said desired shaped rim; overlaying said atleast one design cutout on said plurality of sheets; applying high heatto said glass mold. In one preferred embodiment, the method issandwiching a plurality of resin layers between said plurality ofsheets. In one preferred embodiment, an additional process of coatingthe polyacrylonitrile fibers of said plurality of sheets with resin. Inone preferred embodiment, the method is disposing said design cutoutsuch that the direction of the polyacrylonitrile fibers of said designcutout form an acute angle with the direction of the polyacrylonitrilefibers of said plurality of sheets; In one preferred embodiment, themethod is overlaying a design logo on said plurality of sheets. In onepreferred embodiment, the process includes vacuuming said glass mold,said plurality of sheets, and said at least one design cutout. In onepreferred embodiment, the design-imprinted molded article is a travelluggage. In one preferred embodiment, the design-imprinted moldedarticle is a helmet. In one preferred embodiment In one preferredembodiment, the design-imprinted molded article is a Frisbee. In onepreferred embodiment the design-imprinted molded article is a violin.

In one preferred embodiment the design-imprinted molded article isautomobile component product. In one preferred embodiment. In onepreferred embodiment, the design-imprinted molded article is fashionproducts for man. In one preferred embodiment the design-imprintedmolded article is a furniture product.

In other aspect of the invention, an design-imprinted molded articlecomprising a plurality of sheets of polyacrylonitrile fibers; In onepreferred embodiment polyacrylonitrile fibers overlaying over saidplurality of sheets of polyacrylonitrile fibers and wherein saiddisposed design cutout is such that the direction of thepolyacrylonitrile fibers of said design cutout form an acute angle withthe direction of the polyacrylonitrile fibers of said plurality ofsheets. In one preferred embodiment the polyacrylonitrile fibers iscoated with resin; In one preferred embodiment, the design-imprintedmolded article is a travel luggage. In one preferred embodiment thedesign-imprinted molded article is a helmet. In one preferred embodimentthe design-imprinted molded article is a Frisbee. In one preferredembodiment the design-imprinted molded article is a violin. In onepreferred embodiment the design-imprinted molded article is automobilecomponent product. In one preferred embodiment the design-imprintedmolded article is fashion products for man. In one preferred embodimentthe design-imprinted molded article is a furniture product.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings show illustrative embodiments, but do not depict allembodiments. Other embodiments may be used in addition to or instead ofthe illustrative embodiments. Details that may be apparent orunnecessary may be omitted for the purpose of saving space or for moreeffective illustrations. Some embodiments may be practiced withadditional components or steps and/or without some or all components orsteps provided in the illustrations. When different drawings contain thesame numeral, that numeral refers to the same or similar components orsteps.

FIG. 1 is an illustration of a top perspective view of an article ofluggage.

FIG. 2 is an illustration of a top perspective view of a plurality oflayers.

FIG. 3a is an illustration of a bottom plan view of an interior surfaceof a mold.

FIG. 3b is an illustration of a top plan view of an exterior surface ofa mold.

FIG. 4 is an illustration of a top plan view of a design elementsuperimposed on a first layer in 45-degree angle.

FIG. 5 is an illustration of a right-side view of one or more layersforming a joint.

FIG. 6 is an illustration of a top perspective view of a mold within avacuum seal bag.

FIG. 7A is an illustration of a perspective view of a carbon fiberFrisbee with a design element.

FIG. 7B is an illustration of a perspective view of a carbon violin witha design element.

FIG. 7C is an illustration of a perspective view of a carbon helmet witha design element.

FIG. 8A is a top plan view of a plain weave layer.

FIG. 8B is a top plan view of a twill weave layer.

FIG. 8C is a top plan view of a harness satin weave layer.

DETAILED DESCRIPTION OF THE DRAWINGS

In the following detailed description, numerous specific details are setforth in order to provide a thorough understanding of various aspects ofthe present invention. However, these embodiments may be practicedwithout some or all of these specific details. In other instances,well-known procedures and/or components have not been described indetail so as not to unnecessarily obscure aspects of the embodiments.

While some embodiments are disclosed here, other embodiments will becomeobvious to those skilled in the art as a result of the followingdetailed description. These embodiments are capable of modifications ofvarious obvious aspects, all without departing from the spirit and scopeof protection. The Figures, and their detailed descriptions, are to beregarded as illustrative in nature and not restrictive. Also, thereference or non-reference to a particular embodiment shall not beinterpreted to limit the scope of protection.

In the following description, certain terminology is used to describecertain features of these embodiments. For purposes of thisspecification, unless otherwise specified, the term “substantially”refers to the complete or nearly complete extent or degree of an action,characteristic, property, state, structure, item, or result. The exactallowable degree of deviation from absolute completeness may in somecases depend on the specific context. However, generally speaking, thenearness of completion will be so as to have the same overall result asif absolute and total completion were obtained. The use of“substantially” is also equally applicable when used in a negativeconnotation to refer to the complete or near complete lack of an action,characteristic, property, state, structure, item, or result.

As used herein, the terms “approximately” and “about” generally refer toa deviance of within 5% of the indicated number or range of numbers. Inone embodiment, the term “approximately” and “about”, may refer to adeviance of between 1-10% from the indicated number or range of numbers.

While the invention has application in general to the manufacture ofshaped articles, the manufacture of luggage shells is particularlycontemplated. Accordingly, the invention will be described in detailwith reference to such use.

FIG. 1 is an illustration of a top perspective view of an article ofluggage. As shown in FIG. 1, an article of luggage 100 may comprise oneor more shells 105, 110. The shells 105, 110 may form the front 105 andback 110 panels of the luggage. The luggage 100 may also comprise aplurality of other components such as wheels 115, handle(s) 120,bumper(s) 125, or the like. It should be appreciated that the luggage100 may be any size or shape. Preferably, the luggage 100 is hard-sidedbut it should also be appreciated that the luggage may be soft-sided ora combination thereof. FIG. 1 shows the luggage 100 may be manufacturedby mating two rectangular-shaped and hard-sided shells 105, 110.

Preferably, the shells 105, 110 may be manufactured from any type ofrigid material in order to form hard-sided luggage 100. The rigidmaterial may comprise carbon fiber, thermoplastic, metal or acombination thereof. The rigid material should be characterized as beingstrong and durable yet lightweight, making it an attractive option formanufacturing articles such as luggage 100. Preferably, the rigidmaterial comprises carbon fiber consisting of thin, strong crystallinefilaments of carbon, used as a strengthening material. The carbon fibersmay be about 5-10 micrometers in diameter and comprising substantiallyof carbon atoms.

FIG. 1 also shows the luggage 100 may comprise one or more designelements such as a logo 130. The logo 130 may be adhered to one or moreshells 105, 110 at any time during the manufacturing process. Becausethe shells 105, 110 may be manufactured by overlaying a plurality oflayers within a mold, the logo 130 preferably comprises at least onelayer of the plurality of layers. However, it should be appreciated thatthe logo 130 is not a layer at all and is merely a 3-dimensionalstructure adhered to an outer surface of one or more shells 105, 110.Although the logo 130 may be manufactured from any type of material, thelogo 130 is preferably manufactured from the same type of material asthe plurality layers, for example, carbon fiber.

FIG. 2 is an illustration of a top perspective view of a plurality oflayers. A shell may be manufactured by overlaying a plurality of layers200 within a mold. Preferably, the plurality of layers 200 are combinedat the time of molding however, the plurality of layers 200 can becombined prior to molding by use of a suitable adhesive. If theplurality of layers 200 are combined at the time of molding, theindividual layers 205, 210, 215, 220, 225 can be overlaid in a moldsubjected to heat and pressure to affect a joining together of theindividual layers 205, 210, 215, 220, 225. As shown in FIG. 2, theindividual layers may comprise a first layer 205, a first adhesive 210,a second layer 215, a second adhesive 220, a third layer 225 and so on.

The plurality of layers 200 may comprise a plurality of fiber layers.The plurality of fiber layers may further comprise synthetic or naturalfiber or a combination thereof. Preferably, the plurality of fiberlayers comprise carbon fiber. Almost all carbon fiber is manufacturedfrom a common industrial fiber called polyacrylonitrile fiber, alsoknown as PAN. Most PAN fiber is used to make acrylic fiber. PAN fiber isalso used to make carbon fiber with a pyrolizing process, which means itis heated to high temperatures to remove all elements except the carbon.Most carbon fiber is sold at this point and it has a tensile modulus ofapproximately 33 to 42 million pounds per square inch (MSI), which is ameasurement of stiffness. A higher stiffness per cross sectional arearatio ensures that less material can be used to get the same stiffnessand therefore a resulting in a lighter article. Further processing canyield higher stiffness by making the fiber smaller and denser. However,these fibers are fairly expensive, brittle, and used sparingly. They areknown as High Modulus fiber and are approximately 55 MSI and higher.

The plurality of fiber layers may also be pre-impregnated with a resin.Prepreg is the common term for reinforcing a fiber layer which has beenpre-impregnated with a resin. This resin (i.e., epoxy, phenolformaldehyde or the like) already includes a proper curing agent. As aresult, the prepreg is ready to lay into a mold without the addition ofany more resin. Fabric can be prepegged but most prepreg isunidirectional, meaning it has been spread out onto backing paper. Itcan be spread out in various thicknesses which is indicated with a Gramsper Square Meter (GSM) number. It should be appreciated that varyingthicknesses of carbon fiber may be used. For example, a 210 GSMthickness may be used for a first layer then a 450 GSM thickness may beused for a second layer in order to build the thickness more quickly andcost effectively than using the 210 GSM throughout.

FIG. 3a is an illustration of a bottom plan view of an exterior surfaceof a mold and FIG. 3b is an illustration of a top plan view of aninterior surface of a mold. Luggage may comprise one or more concaveand/or convex parts. In order to manufacture concave and/or convexparts, an exterior surface 305, as shown in FIG. 3a , and/or an interiorsurface 310, as shown in FIG. 3b , of a mold 300 may be utilized.

In one embodiment, a shell may be manufactured by applying and coveringa surface of a mold 300 with a layer of release agent then overlaying afirst layer into the mold and then applying and covering the first layerwith a layer of resin. It should be appreciated that if the first layerhas been pre-impregnated with a resin, then it is not necessary tofurther apply and coat the first layer with a layer of resin. The firstlayer may be overlaid into the mold 300 substantially contacting theentire surface of the mold. In order to achieve this, the process ofoverlaying may start at a center point 315 of the mold 300 and then thefirst layer may be pressed into the corners and features of the mold 300working outward 320.

It should be appreciated that a first layer may be measured and trimmedaccording to mold specifications prior to being overlaid into the mold300. However, substantially unadhered portions of the first layerextending beyond an edge 325 of the mold may be trimmed or maintaineduntrimmed. If the unadhered portions are maintained untrimmed, anadhesive may be applied to an outer surface of the unadhered portions.Accordingly, the outer surface of the unadhered portions may wrap aroundthe edge 325 of the mold 300 and adhere to an opposing surface of themold 300. For example, when unadhered portions are extending beyond theedge 325 of an exterior surface 305 of a mold 300, the unadheredportions may wrap around the edge 325 of the mold and adhere to aninterior surface 310 of the mold 300.

To maintain strength and durability, the process of overlaying the firstlayer into the mold 300 and applying and covering the first layer with alayer of resin can be repeated numerous times with subsequent layers(i.e., a second layer, third layer, fourth layer, etc.) until thedesired amount of layers and thickness is reached. Then a vacuum bag maybe utilized to cure and hold the layers together, removing air andimpregnating the fibers of the layers with the resin, thereby hardeningand setting the article. After curing, the layers and the mold 300 areseparated to define a molded article having a surface and structurecorresponding to the mold 300.

Although FIG. 3 shows one mold 300, it should be appreciated that morethan one mold can be used depending on the size, shape and/or type ofarticle to be manufactured. It should be further appreciated thatdifferent types of mold(s) can be used. For instance, a glass mold canbe used. However, polyester fiberglass molds are typically unfavorablebecause their low surface temperature can result in separation of thelayers. Polyurethane molds are also typically unfavorable because theycan result in cure inhibition.

FIG. 4 is an illustration of a top plan view of a design elementsuperimposed on a first layer. As shown in FIG. 1, luggage may alsocomprise one more design elements, such as a logo. FIG. 4 shows a designelement 400 adhered to a first layer 405 of carbon fiber. The designelement 400 preferably comprises at least one layer of carbon fiberrotated with respect to the first layer 405 such that the direction ofthe carbon fibers of the design element 400 are juxtaposed with respectto the direction of the carbon fibers of the first layer 405. The designelement and the first layer each comprise fibers aligned in a homogenousparallel direction. When the design element is rotated and placed uponthe first layer it creates a visible contrast. Preferably, the designelement 400 is rotated 45 to 90 degrees with respect to the first layer405. However, as little as 15 degrees in rotation can also result in anoticeable contrast between the carbon fibers of the design element andthe first layer 400, 405. Ideally, the rotation results in the carbonfibers of the design element 400 substantially perpendicular to thecarbon fibers of the first layer 405. In this manner, the design element400 and the first layer 405 form a substantially ornamental and visuallyappealing layer.

However, since the design element 400 may also comprise at least onelayer of carbon fiber, the design element 400 may also contribute to theoverall structural integrity of the molded article. Furthermore, themethod described herein permits the incorporation of one or more designelements 400 into molded articles which was previously unattainable.Accordingly, when it is desired to place a logo onto an article ofluggage, the method described herein provides a means to do so. Itshould be appreciated that a design element 400 may be adhered to layersother than the first layer 405 (i.e., a second layer, third layer,fourth layer, etc.) depending on the effect to be achieved.

FIG. 5 is an illustration of a right-side view of one or more layers ofmaterial forming a joint. Preferably, layers overlaid into a moldcontact the entire surface of the mold. However, corners and features ofthe mold may create unwanted gaps or spaces 500 in between the mold 505and a first layer 510 or in between subsequent layers. In order toprevent this, multiple layers may be overlaid at the corners andfeatures of the mold 500 and pressed into the corners and features suchthat the layers contact the entire surface of the mold.

FIG. 6 is an illustration of a top perspective view of a mold within avacuum seal bag. Preferably, the mold 600 is vacuum sealed to compressthe mold 600 and evacuate air trapped between the plurality of layersand the surface of the mold 600. In this manner, the number of surfacedefects on the final product is minimized.

Vacuum sealing can be automated using equipment specifically designed tovacuum seal materials on an industrial/commercial scale. The plasticfilm the mold 600 is sealed into may be provided as a bag 605. However,the plastic film is also typically sold on rolls in what is termed a CFold configuration. In a C Fold configuration, a length of film isunrolled and the edge coming off the roll is sealed using a heat sealer.The mold 600 is then placed between two layers of film, i.e., in the CFold configuration. The film is further cut and sealed and trapped airis evacuated. It is not a necessity that the sealing be effected byheat. Adhesive sealing is acceptable so long as the vacuum conditionsare achieved and maintained. Heat sealing is, however, preferred.

After vacuum sealing, the mold 600 is subjected to oven curing such thatthe mechanical properties of the article can be realized.

FIG. 7a is an illustration of a perspective view of a frisbee with adesign element. FIG. 7b is an illustration of a perspective view of aviolin with a design element. FIG. 7c is an illustration of aperspective view of a helmet with a design element. FIGS. 7a to 7c showthe wide applicability of placing a design element on a molded article.Although the mold has been described herein as a mold for an article ofluggage, it should be appreciated that any mold can be used. Preferably,the mold will be any mold known in the field of carbon fiber. Examplesof such molds include for articles such as outdoor equipment, jewelry,electronics, instruments, vehicle parts, weapons, personal accessories,etc.

FIG. 8a is a top plan view of a plain weave layer. FIG. 8b is a top planview of a twill weave layer. FIG. 8c is a top plan view of a harnesssatin weave layer. As shown in FIGS. 8a to 8c , the layers can comprisevarious weave patterns. Preferably, the design element and the layersare of the same weave pattern. It should be appreciated that the designelement and the layers can be different patterns rotated with respect toeach other to create a visible contrast. The various weave patterns cancontribute not only to the overall visual appearance of the moldedarticle, but also to the overall structural integrity of the moldedarticle.

Unless otherwise stated, all measurements, values, ratings, positions,magnitudes, sizes, locations, and other specifications that are setforth in this specification, including in the claims that follow, areapproximate, not exact. They are intended to have a reasonable rangethat is consistent with the functions to which they relate and with whatis customary in the art to which they pertain.

The foregoing description of the preferred embodiment has been presentedfor the purposes of illustration and description. While multipleembodiments are disclosed, still other embodiments will become apparentto those skilled in the art from the above detailed description. Theseembodiments are capable of modifications in various obvious aspects, allwithout departing from the spirit and scope of protection. Accordingly,the detailed description is to be regarded as illustrative in nature andnot restrictive. Also, although not explicitly recited, one or moreembodiments may be practiced in combination or conjunction with oneanother. Furthermore, the reference or non-reference to a particularembodiment shall not be interpreted to limit the scope of protection. Itis intended that the scope of protection not be limited by this detaileddescription, but by the claims and the equivalents to the claims thatare appended hereto.

Except as stated immediately above, nothing that has been stated orillustrated is intended or should be interpreted to cause a dedicationof any component, step, feature, object, benefit, advantage, orequivalent, to the public, regardless of whether it is or is not recitedin the claims.

I claim: 1) A method of manufacturing a design-imprinted molded articlecomprising: a) providing a glass mold of a desired shape; b) said glassmold further comprises a desired shaped concave and a desired shapedrim; c) providing a plurality of sheets of polyacrylonitrile fibers; d)providing at least one design cutout of polyacrylonitrile fibers; e)overlaying said plurality of sheets on the surface of said desiredshaped concave and said desired shaped rim; f) overlaying said at leastone design cutout on said plurality of sheets; g) applying high heat tosaid glass mold; h) sandwiching a plurality of resin layers between saidplurality of sheets; i) coating the polyacrylonitrile fibers of saidplurality of sheets with resin; j) disposing said design cutout suchthat the direction of the polyacrylonitrile fibers of said design cutoutform an acute angle with the direction of the polyacrylonitrile fibersof said plurality of sheets. 2) The method of claim 1, whereinoverlaying a design logo on said plurality of sheets; 3) The method ofclaim 1, wherein vacuuming said glass mold, said plurality of sheets,and said at least one design cutout. 4) The method of claim 1, whereindesign-imprinted molded article is a travel luggage. 5) The method ofclaim 1, wherein design-imprinted molded article is a helmet. 6) Themethod of claim 1, wherein design-imprinted molded article is a Frisbee.7) The method of claim 1, wherein design-imprinted molded article is aviolin. 8) The method of claim 1, wherein design-imprinted moldedarticle is automobile component product. 9) The method of claim 1,wherein design-imprinted molded article is fashion products for man. 10)The method of claim 1, wherein design-imprinted molded article is afurniture product.